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The side wall outer panel is the largest and most critical part in the outer cover of automobile, its structure is complex and changeable, and the surface quality requirements are extremely high. Therefore, first, the cross-sections at eight typical positions of the side wall outer panel were selected for structural analysis, and the change conditions of cross-section lines at different positions were obtained. Then, the process supplementary cross-section lines at key positions such as rear lamp area with complex deformation, overlapping area between upper side and top cover and upper side area of front door were analyzed, which laid the foundation of process design. Furthermore, AUTOFORM and other softwares were used to supplement the process of side wall outer panel and calculate the blank formed by drawing, a three-step blanking process was designed, and a set of blanking progressive die for the side wall outer panel was designed based on the blanking process. Finally, according to the blanking blank, the complete process of five forming processes for side wall outer panel including drawing, trimming+punching, trimming+shaping, punching+flanging and punching+flanging+cutting was designed.
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